Hemp building material

ABSTRACT

A hemp building material for creating a reinforced structure utilizing hemp fibers. The hemp building material includes an elongate structure having a plurality of bast fibers contained within the elongate structure. The bast fibers are orientated substantially parallel to the longitudinal axis of the elongate structure. The bast fibers are preferably positioned within the lower portion of the elongate structure to provide tensile resistance to the elongate structure during the supporting of a vertical load. The elongate structure may have various configurations and may be constructed of various materials such as but not limited to plastic and composite materials.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates generally to building materials and more specifically it relates to a hemp building material for creating a reinforced structure utilizing hemp fibers.

[0003] Hemp is comprised of strong woody fibers referred to as “bast fibers”. Bast fibers are generally stiffer and stronger than conventional fibers such as cotton fibers. Hemp is currently utilized to construct clothing, paper and various other products because of its inherent strength.

[0004] 2. Description of the Prior Art

[0005] Conventional building materials have been in use for years. Plastic boards have been in use for years as manufactured by RENEW PLASTICS. Board members may also be constructed of various types of composite materials. Board members may be constructed utilizing various methods/processes including crushing, rolling, extrusion or molding.

[0006] Building materials such as concrete have also been in use for years. Concrete is capable of forming elongate structures that are able to support significant vertical loads by the usage of steel rebar within the lower portions of the concrete during the pouring of the concrete. The steel rebar has a high tensile strength which compensates for the low tensile strength of the concrete which has a high compression strength. During the application of a load to a concrete structure reinforced with steel rebar, the upper layer of the concrete is under “compression” and the lower layer of the concrete is under “expansion”. The steel rebar prevents the lower layer of the concrete from separating due to the low tensile strength of the concrete.

[0007] The main problem with conventional plastic and composite boards is maintaining tensional support when a vertical load is placed upon an elongate board. Another problem with conventional plastic and composite boards is maintaining a lightweight structure while simultaneously maintaining the overall tensional strength.

[0008] Examples of patented building structures which are illustrative of such prior art include U.S. Pat. No. 5,741,589 to Fujii et al.; U.S. Pat. No. 5,473,849 to Jones, Jr. et al.; U.S. Pat. No. 4,947,611 to Otsuka; U.S. Pat. No. 3,949,144 to Duff; U.S. Pat. No. 5,727,356 to Ensinger et al.; U.S. Pat. No. 5,865,007 to Bowman et al.; U.S. Pat. No. 5,904,963 to Blatter. The above references are hereby incorporated by reference for the purposes of constructing various building materials and structures.

[0009] While these devices may be suitable for the particular purpose to which they address, they are not as suitable for creating a reinforced structure utilizing hemp fibers. Conventional composite and plastic building materials do not have the maximum strength to weight ratio.

[0010] In these respects, the hemp building material according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of creating a reinforced structure utilizing hemp fibers.

SUMMARY OF THE INVENTION

[0011] In view of the foregoing disadvantages inherent in the known types of building materials and structures now present in the prior art, the present invention provides a new hemp building material construction wherein the same can be utilized for creating a reinforced structure utilizing hemp fibers.

[0012] The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new hemp building material that has many of the advantages of the building materials and structures mentioned heretofore and many novel features that result in a new hemp building material which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art building materials and structures, either alone or in any combination thereof.

[0013] To attain this, the present invention generally comprises an elongate structure having a plurality of bast fibers contained within the elongate structure. The bast fibers are orientated substantially parallel to the longitudinal axis of the elongate structure. The bast fibers are preferably positioned within the lower portion of the elongate structure to provide tensile resistance to the elongate structure during the supporting of a vertical load. The elongate structure may have various configurations and may be constructed of various materials such as but not limited to plastic and composite materials.

[0014] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and that will form the subject matter of the claims appended hereto.

[0015] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.

[0016] A primary object of the present invention is to provide a hemp building material that will overcome the shortcomings of the prior art devices.

[0017] A second object is to provide a hemp building material for creating a reinforced structure utilizing hemp fibers.

[0018] Another object is to provide a hemp building material that may be utilized various building structures such as board members, I-beams, beam members, columns, and panels.

[0019] An additional object is to provide a hemp building material that utilizes the unique tensile strength of hemp fibers.

[0020] A further object is to provide a hemp building material that utilizes the entire hemp stalk without retting.

[0021] Another object is to provide a hemp building material that does not separate the long and short hemp fibers.

[0022] A further object is to provide a hemp building material that provides increased strength with less mass and weight.

[0023] Another object is to provide a hemp building material that utilizes an easily renewable raw material.

[0024] Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages are within the scope of the present invention.

[0025] To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:

[0027]FIG. 1 is an upper perspective view of a board member containing a plurality of bast fibers.

[0028]FIG. 2 is a cross sectional view taken along line 2-2 of FIG. 1.

[0029]FIG. 3 is a top view of the board member.

[0030]FIG. 4 is a cross sectional view taken along line 4-4 of FIG. 2.

[0031]FIG. 5 is an upper perspective view of the I-beam version of the present invention.

[0032]FIG. 6 is a cross sectional view taken along line 6-6 of FIG. 5.

[0033]FIG. 7 is an upper perspective view of the beam member version of the present invention.

[0034]FIG. 8 is a cross sectional view taken along line 8-8 of FIG. 7.

[0035]FIG. 9 is an upper perspective view of a tubular beam member having a rectangular cross sectional area.

[0036]FIG. 10 is a cross sectional view taken along line 10-10 of FIG. 9.

[0037]FIG. 11 is an upper perspective view of a tubular column having a circular cross sectional area.

[0038]FIG. 12 is a cross sectional view taken along line 12-12 of FIG. 11.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0039] Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIGS. 1 through 12 illustrate a hemp building material 10, which comprises an elongate structure 20, 30, 40, 50, 60 having a plurality of bast fibers 20 contained within the elongate structure 20, 30, 40, 50, 60. The bast fibers 20 are orientated substantially parallel to the longitudinal axis of the elongate structure 20, 30, 40, 50, 60. The bast fibers 20 are preferably positioned within the lower portion of the elongate structure 20, 30, 40, 50, 60 to provide tensile resistance to the elongate structure 20, 30, 40, 50, 60 during the supporting of a vertical load. The elongate structure 20, 30, 40, 50, 60 may have various configurations and may be constructed of various materials such as but not limited to plastic and composite materials.

[0040] Bast fibers 20, particularly those of hemp, possess by nature a high degree of tensile strength not commonly found in other fiber materials thereby making them suitable for usage in building materials. Hemp is commonly “retted” which is the process of exposing the hemp stalks to moisture and the elements to allow bacteria to digest the lignins (i.e. gummy material) that hold the fiber strands to the rest of the stalk, and is dependent upon the weather conditions. The current process contained within the present invention does not utilize the process of retting as the entire hemp stalk is preferably utilized.

[0041] The present invention is comprised of an elongate structure 20, 30, 40, 50, 60 as illustrated in FIGS. 1 through 12 of the drawings. The elongate structure 20, 30, 40, 50, 60 may be formed utilizing various materials and chemicals such as plastic, composite materials or other common building materials. The elongate structure 20, 30, 40, 50, 60 may be formed by various conventional processes such as but not limited to pressing, molding or extrusion.

[0042] The elongate structure 20, 30, 40, 50, 60 may be formed into various shapes and structures as illustrated in FIGS. 1 through 12 of the drawings. The elongate structure 20, 30, 40, 50, 60 may be comprised of a board member 30 30, an I-beam 40 40, a beam member 50 50, or a tubular column 60 60. The bast fibers 20 are preferably positioned within the lower portion of the elongate structure 20, 30, 40, 50, 60 to provide increased tensile strength to the elongate structure 20, 30, 40, 50, 60 while under a vertical load.

[0043] As shown in FIGS. 1 through 4 of the drawings, the board member 30 is comprised of an upper surface 32 and a lower surface 34. The bast fibers 20 are preferably at least positioned within the lower layer of the board member 30, however the bast fibers 20 may be positioned through the entire board member 30 as shown in FIGS. 1 and 2 of the drawings. The bast fibers 20 are preferably comprised of the entire hemp stalk without the retting process applied to effectively utilize the long and short fibers 20 within the hemp stalk. The board member 30 may have various lengths, cross sectional shapes and thickness.

[0044] As shown in FIGS. 5 and 6 of the drawings, the I-beam 40 is comprised of an upper member 42, a middle member 44 extending orthogonally from the upper member 42, and a lower member 46 attached to the middle member 44 orthogonally and opposite of the upper member 42. The bast fibers 20 are preferably at least positioned within the lower member 46 of the I-beam 40 as clearly shown in FIGS. 5 and 6 of the drawings. However, the bast fibers 20 may be positioned through the entire I-beam 40 including the middle member 44 and the upper member 42. The bast fibers 20 are preferably comprised of the entire hemp stalk without the retting process applied to effectively utilize the long and short fibers 20 within the hemp stalk. The I-beam 40 may have various lengths, cross sectional shapes and thickness.

[0045] As shown in FIGS. 7 and 8 of the drawings, the beam member 50 is comprised of an upper edge 52 and a lower edge 54. The bast fibers 20 are preferably at least positioned within the lower layer of the beam member 50 as shown in FIGS. 7 and 8 of the drawings. However, the bast fibers 20 may be positioned through the entire beam member 50 in an alternative embodiment. The bast fibers 20 are preferably comprised of the entire hemp stalk without the retting process applied to effectively utilize the long and short fibers 20 within the hemp stalk. The board member 30 may have various lengths, cross sectional shapes and thickness. As shown in FIGS. 9 and 10, a tubular beam member 50 includes a passage 56 with the bast fibers 20 within the lower portion of the beam member 50.

[0046] As shown in FIGS. 11 and 12 of the drawings, the column 60 is comprised of an inner wall 64 and an outer wall 62. The bast fibers 20 are preferably at least positioned within the central portion of the column 60 between the inner wall 64 and the outer wall 62. However, the bast fibers 20 may be positioned through the entire column 60 in an alternative embodiment. The bast fibers 20 are preferably comprised of the entire hemp stalk without the retting process applied to effectively utilize the long and short fibers 20 within the hemp stalk. The column 60 may have various lengths and thickness.

[0047] The raw hemp material may be crushed while maintaining the longitudinal orientation of the bast fibers 20. After the bast fibers 20 are prepared, they are mixed within binding agents such as plastic, resin or composite material to construct the elongate structure 20, 30, 40, 50, 60. The mixture of bast fibers 20 and binding agent is then formed into the desired elongate structure 20, 30, 40, 50, 60 by using a pressing process, extrusion process or molding process. The bast fibers 20 are preferably orientated longitudinally within the elongate structure 20, 30, 40, 50, 60 and are preferably positioned within the lower portion of the elongate structure 20, 30, 40, 50, 60 to provide maximum tensile strength to the elongate structure 20, 30, 40, 50, 60 during a vertical load.

[0048] As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.

[0049] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed to be within the expertise of those skilled in the art, and all equivalent structural variations and relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

[0050] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. Index of Elements for Hemp Building Material □ ENVIRONMENTAL ELEMENTS □ □ □ □ □ □ □ □ □ □ 10. Hemp Building Material □ 11. □ 12. □ 13. □ 14. □ 15. □ 16. □ 17. □ 18. □ 19. □ 20. Bast Fibers □ 21. □ 22. □ 23. □ 24. □ 25. □ 26. □ 27. □ 28. □ 29. □ 30. Board Member □ 31. □ 32. Upper Surface □ 33. □ 34. Lower Surface □ 35. □ 36. □ 37. □ 38. □ 39. □ 40. I-Beam □ 41. □ 42. Upper Member □ 43. □ 44. Middle Member □ 45. □ 46. Lower Member □ 47. □ 48. □ 49. □ 50. Beam Member □ 51. □ 52. Upper Edge □ 53. □ 54. Lower Edge □ 55. □ 56. Passage □ 57. □ 58. □ 59. □ 60. Column □ 61. □ 62. Outer Wall □ 63. □ 64. Inner Wall □ 65. □ 66. □ 67. □ 68. □ 69. □ 70. □ 71. □ 72. □ 73. □ 74. □ 75. □ 76. □ 77. □ 78. □ 79. 

I claim:
 1. A building material, comprising: an elongate structure having an upper layer and a lower layer; and a plurality of bast fibers positioned longitudinally within said elongate structure.
 2. The building material of claim 1, wherein said plurality of bast fibers are positioned within said lower layer of said elongate structure.
 3. The building material of claim 2, wherein said bast fibers are comprised of a hemp material.
 4. The building material of claim 3, wherein said hemp material is comprised of a plurality of hemp stalks.
 5. The building material of claim 4, wherein said hemp stalks are positioned parallel to one another within said lower layer.
 6. The building material of claim 5, wherein said elongate structure is comprised of a board member having an upper surface and a lower surface.
 7. The building material of claim 5, wherein said elongate structure is comprised of an I-beam having an upper member, a middle member and a lower member.
 8. The building material of claim 7, wherein said lower member of said I-beam comprises said lower layer of said elongate structure.
 9. The building material of claim 5, wherein said elongate structure is comprised of a beam member having an upper edge and a lower edge.
 10. The building material of claim 9, wherein said beam member includes a passage.
 11. The building material of claim 10, wherein said beam member has a rectangular shape with a lower portion and an upper portion, wherein said lower portion includes a plurality of bast fibers forming a U-shape.
 12. The building material of claim 5, wherein said elongate structure is comprised of a column having an inner wall and an outer wall, wherein said plurality of bast fibers are positioned between said inner wall and said outer wall.
 13. A method of manufacturing a building material containing bast fibers, comprising the steps of: (a) providing a plurality of bast fibers and a volume of binding agent; (b) mixing said bast fibers with said binding agent into a mixture; and (c) forming said mixture into an elongate structure with said bast fibers orientated along a longitudinal axis of said elongate structure.
 14. The method of manufacturing the building material containing bast fibers of claim 13, wherein said bast fibers are comprised of hemp material.
 15. The method of manufacturing the building material containing bast fibers of claim 14, wherein said hemp material is comprised of a plurality of whole hemp stalks.
 16. The method of manufacturing the building material containing bast fibers of claim 15, wherein said step of forming said mixture into an elongate structure is comprised of an extrusion process.
 17. The method of manufacturing the building material containing bast fibers of claim 15, wherein said step of forming said mixture into an elongate structure is comprised of a pressing process.
 18. The method of manufacturing the building material containing bast fibers of claim 15, wherein said step of forming said mixture into an elongate structure is comprised of a molding process.
 19. A method of manufacturing a building material containing bast fibers, comprising the steps of: (a) providing a plurality of bast fibers and a volume of binding agent; (b) positioning said bast fibers parallel to one another within a mold; (c) dispensing said binding agent upon said bast fibers within said mold forming an upper layer and a lower layer, wherein said lower layer completely encloses said bast fibers; and (d) allowing said binding agent to harden about said bast fibers.
 20. The method of manufacturing the building material containing bast fibers of claim 19, wherein said bast fibers are comprised of hemp material having a whole stalk structure. 